Resistance welding apparatus



April 4, 1950 RAVA RESISTANCE WELDING APPARATUS Original Filed Oct. 11, 1940 aituok l kogta Patented Apr. 4, 1950 UNITED STATES PATENT OFFICE RESISTANCE WELDING APPARATUS Alexander Rava, Jersey City, N. J.

Original application October 11, 1940, Serial No.

360,721. Divided and this application September 19, 1941, Serial No. 411,514

7 Claims. 1

This application is a division of my copending application Serial No. 360,721, filed October 11, 1940, now abandoned.

This invention relates to a new and improved method and apparatus for resistance welding which employs a power condenser or capacitor in the primary circuit of a welding transformer for apportioning the energy to be applied to the work between the welding electrodes connected to the secondary of said transformer.

It has heretofore been suggested, for example in the Welding Journal for August 1935, in a paper by G. I. Babat, pages 6 to 8 inclusive, and in Sidney Patent No. 2,119,105, issued November 7, 1939, that a power condenser may be used in resistance: welding, the power condenser to be first charged and then its energy released through the primary of a welding. transformer. The present invention is an improvement on said prior system in respect tothe cycle of operation, efficiency and consistency of performance.

A feature of my invention is the employment of a power condenser in conjunction with awelding transformer which permits surges of welding current tobe delivered. to said transformer alternately in opposite vectorial directions.

Another feature of my invention is the provision of a pair of controllable unidirectionaldevices' in conjunction with a power condenser and a welding transformer which permit surges of current through said. welding transformer alternately in opposite vectorial directions.

Another feature of invention is the provision of means for adjusting, within very close limits but with wide latitude, the amplitude and duration of the welding current surges so that they may be adjusted to values closely commen surate with the physical properties and thick,

nesses. of the work pieces being welded.

Another feature of my invention is the provi' sion of means for extending the duration of the surges of welding current beyond limits possible with present systems, while adjusting the amplitude of. the current to a desired value.

Another feature of. my invention is the provision. of means for insuring reliably consistent- Welding performance, by reason of the symmetryand balance of the electrical. circuits.. and. by. the. provision of. controlling means for. the switching devices.

Another feature. of my invention is the ability of my device to perform welding operations at.

greatly increased efliciency over the prior power condenser resistance welders;

Another featureof. my invention is the provh sion of a power condenser welding circuit which permits the efficient utilization of a closed core welding transformer of suitable dimensions for optimum efficiency in the welding job to be performed.

Another feature of my invention is the ability of my welder to do seam welding as well as spot welding.

Another feature of my invention is the ability of my welder to weld work pieces of considerable difference in thickness as well as in composition and physical and metallurgical properties.

In the drawing, the figure shows a circuit dia gram of an embodiment of my invention in which a power condenser is charged alternately t0 opposite polarity and in which surges of current are supplied to the primary of the welding transformer alternately in opposite vectorial directions during the discharge of the condenser.

There are shown in the drawings six gas-filled grid controlled rectifier tubes of the thyratron type, HI to H6 inclusive, although any other type of tubes with controlled discharge, such as ignitrons, may likewise be used. Said tubes ill to H6 serve as unidirectional switching devices, as will be explained. A plurality of sources of current, which are illustrated as batteries H IE to HBB, inclusive provide the respective grid voltages required for the control of these six. tubes. A power condenser 21, which may be a bank of condensers in parallel, is connected effectively across the primary winding i8, 24 of a welding transformer 44, and in series with thetubes H3 and I I6 which are poled to pass cur rent in opposite directions when suitably energized.

A synchronous motor 18 drives a plurality of discs IIIA to NBA having conductive inserts 21 to 32 adapted at properly timed intervals to makecontact with brushes 21A, 21B, 28A, 28B, 29A, 2913, 30A, 30B, 31A, 3IB, 32A and 32B, respectively, in order to apply at the suitable prede termined moments the desired grid voltage impulses to the tubes Ill to MB for the purpose of actuating the respective discharges through them or firing. them. A timer 52. run by current from the leads 63, having starter buttorr operating through leads 64, is provided to: corn 'trol the number of welding shots to be given the work per spot when the device.- is used for spot welding.

In the operation of the circuit shown in the drawing, a source of power will be connected to the transformer or rectifier 9'2 from: a sourcemanked A. C. supply. Assuming: that a transductive or firing the same (and provided that Y the power condenser 2| has not any charge of equivalent potential but of opposite polarity), a current will flow from the secondary of the power transformer through lead I6, tube II I, and leads 23 and 39 to the plate 22 of the power condenser 2|, and from the plate of said condenser through lead I0, tube H2, and lead 33 back to the opposite terminal of the power transformer 9|. Said current will result in charging said power condenser ill. said firing, grid voltage impulse in the tubes HI and H2 are produced when the copper inserts 21 and 28 are in contact simultaneously with brushes 21A, 21B, and 28A and 288, respectively, as illustrated in the drawing. It will be noted that when either of these brushes is not in contact with said copper inserts, a circuit may be traced, for example, from the grid of tube III through lead IE to the negative terminal of battery IIIB, thence to the intermediate terminal of that battery and through lead TI to the cathode of tube'IIi. A similar circuit may be traced from the grid and cathode of tube I I2 to the battery H213. Thus there will be during the greater part of each revolution of the discs IIIA and HM. a negative bias on the grids of tubes III and H2 in respect to their cathodes, preventing flow of current through said tubes.

At the instant we are now considering, when brushes 21A and 21B, and 28A and 28B make a simultaneous contact with their respective copper inserts 2'! and 28, a circuit may be traced, for example, from the grid of tube I II through leads I3 and I8 to the timer 62 where contact will be made between the leads I8 and "I9, provided button 65 is pushed down to make contact with leads 64, so that the circuit may continue to be traced from. lead I9 to brush 21A, insert 21,

brush 21B, and lead 80 to the extreme positive terminal of battery IIIB, thence through the left portion of that battery and through lead" to the cathode of tube Ill. The synchronous motor I8 and the conductive insert 21 will be so adjusted that brushes 21A and NB make contact with insert 2! at a desired predetermined moment, which, according to selection, may be set to occur prior to the peak positive voltage on the secondary of transformer 9|, or at its peak, or again at any time during the decline of said positive voltage. The above adjustment is one of several effective means for regulation of energy used for welding, any given setting in regard to voltage conditions remaining constant during operation, since the peripheral velocity of disc IIIA, driven by synchronous motor 18 isin step with the speed of voltage alternations and in step with the secondary of power'trans- V lead I0, battery II2B, and lead. to the cathode of tube I I2, to fire that tube simultaneously with--' the firing of tube III and in the same manner.

Because the peripheral extension of the conductive inserts 21 and 28 are but a small fraction of the total periphery of discs IIIA and II2A, and because the brushes 21A and 21B and 28A and 28B are mounted in close proximity to each other, the span of time during which said brushes are simultaneously in contact with said inserts is rather small in comparison with the time required for one complete revolution of the discs, which, of course, constitutes the cycle of operation. It is evident, therefore, that the positive voltage impulse produced by batteries IIIB and H23 on the grids of tubes III and H2 is of very small duration, said grids being cathodes of said tubes comes to an end. Thisv happens when the voltage on the terminals of power condenser 2 I, due to the increasing charge on its plates 20 and 22, balances the voltage of the secondary of the power supply transformer 9 I. The current in the circuit through tubes I I I, I I2 and power condenser 2|, then ceases to flow, thus allowing the grids of the tubes III and H2 to regain their control.

The time required for the above chargin of power condenser 2I depends upon the electrical parameter of the charging circuit. In smaller units said charging time may be only a few hundred micro-seconds, whereas large welders may require 5000 or more micro-seconds.

After a suitable period or pause, the duration. of which may be selected as of a second after tubes III and H2 cease firing in case the power transformer BI is used, the tube II3 will; be fired. It will be noted that this tube normally has a negative bias on its grid from battery I I313" which may be traced similarly to battery IIIB.

When the tube H3 is to be fired, the copper insert 3| will be moved to a position where it is in contact with the brushes 3IA, 3IB, and will apply a positive potential to the grid of tube II3 II3B' through the leads 86, 81, copper insert 3I and from the left hand portion of battery brushes 3| A and 3IB. At the instant when the brushes 3IA and neously with the insert 3 I, thus permitting a positive voltage on the grid of tube I I3, tube I I3 will:

fire, permitting discharge of the power condenser 2| through a circuit which may be traced from plate 22, through lead 39, tube II3, lead 15,

primary winding I8, 24 and leads 89 and I9 to the plate 20 of condenser 2|.

During this discharge of current from condenser 2 I, the current through the primary winding I8, 24 of the welding transformer will induce a current in the secondary 45 thereof which will be'applied 'bythe leads, 41 to the electrodes 48 and 49 and thence to the work 50, 5| giving a" welding current impulse.

The duration of the power condenser discharge depends upon the electrical parameters of the discharge circuit, and, subject to the values involved, has a range from about 200 micro-seconds to 5000 or more micro-seconds. In general the discharge time tends to be shorter than the charging-time because-thecharging circuit by However,

3IB make contact simultaits very nature has tocontain indispensable source of energy, the internal impedance "of which is anadded factor inthe' charging circuit.

Shortly after. the positive grid voltage impulse initiating the'flring of the discharge tube H3 is made, the brushes 3| Aland 3|Biwiil'cease1rnaking the J simultaneous contact with copper: insert 3|, .andoa negative bias-will .berestored -to the gridoftubeiifi Jirom'the battery H3B. However, said grid of tube H3-will-regain itszactual control and bar any "further unwanted a renewal of discharge through tube l 3 only "after athe- :potential' difference between theanodetan'd cathode ofsaid tube has sunk during "the discharge of the'ipower condenser 2 I :to less than the? internal arc drop (which has a normalrange o'fapproximately 5 to 25 volts) of tube H3.

Although durin "the :com-se of fthe yldischarge operation the voltage between ithe terminals oi the power condenser "2| --will,xaftersa rapid decline; reach zero in ':a" very "short time (approximately :a few hundredrmicro-seconds) the "current in the discharge circuit .39, H3, 15, i8, 224, -89 and H will "still continue; to flow for'some'time (for about a .few ten or even hundreds microseconds), with arapidly diminishing intensity in "the same vectorial direction as the current originally caused bythe fully charged power condenser 2|.

This lagging oizthe current, following-the well known Lenzs law, isdue to the potential'difference of concurring vectorial direction between the-terminal leads Hand 89 of theprimar sby the still collapsing magnetic'field of thewelding transformer, whichthus is assuming now for a brief period the role of anenergysource. Since, according to Lenzs law, saidpotential'diflerence has the'same vectorial direction a the original potential difference between the plates ;2||.-andf122 of the power condenser 2| (plate 22being positivewith respect to plate -2U),uat the beginning of its discharge, the resultant potential difference beween the terminal leads and 89 will alsohave the same vectorial dire'ction,'that is. 15 will still be positive with'respect to-B B during and for some time after the rapidly declining charge of condenser 2| is completely exhausted. and thus the formerly positive potential difference between and 22 is equaltozero.

Due to the above-mentioned persistence of positive potential of 15 with respect to l9 the anode of tube H3 will also persist inf'remaining positive in respect to its cathode, with the're'sult that despite the fact that the grid of tube I I3 has already been made negative in respect to its cathode by the rotary motion of disc H3A, disengaging the simultaneous contact of brushes 3 IA and 3|B with conductive insert 31, acurrent will be passing through said tube H3 'duringrand for some time after the positive potential of plate 22 in'respect to plate 20:..of'conde'nser 2| declines to zero, thus pumping into the power condenser 2| by the action of the collapsing magnetic field of the welding transformer, ibynow empty of the original charge, an electric charge of a polarity inverse to that of the original charge. iSaid'charge of inverse potential of "condenser'2 I, dependin uponthe values of the'electrical parameters of "the J discharge-circuit 22, 39, H3, 15,18, 24, 89, |9,may1reach I5','25 or more percent of the 'originalcharge ofsaid condenser 2|.

Such energy of inverse potential-stored in condenser 2| remains trapped'therein'due-to the-valve action of tube "I I3 which barsany current -surgesof 'inverse' direction from its cathode-to its anode. The tube -I Hi, which is inparallel with tube "I I3, also bars "any current surges of inverse'direction by reason of the fact that it: is not in firing condition'at-the proper time to'permit such surges to pass.

During the next half cycle of currentin the power transformer 91, thelead l6 connected to the-secondary of the transformer is again'positive and the lead 32 negative, thus coinciding in vector-ial direction-with the forward voltage of the gas filledgrid-controlled rectifier tubes H4 and H5. If now at a suitable preselected moment during this forward half cycle a proper voltage impulse'is applied to the grids of tubes H4 and H5, in respect to their cathodes, thusmaking thesextubes .conductive'or firing thesame, a current :will flow from thesecondary of the power transformer through lead 16, tube I I4, and'lead Hi "to the plate 20 of'the'power condenser 2|, and from. the plate "22 of said condenser through leads 39 and 23, tube H5; and lead 33 back to the opposite terminal of the power'transformer 9l. Said current will result in charging said'power condenserZl. Said firing grid voltageimpulse inthe tubes H4 and H5 are produced when the copper inserts 23 and '30 are in contact simultaneously with brushes 29A, 29B, and 30A and 3llB,:respectively. It will be noted that when either of these brushes is not in contact with said copper inserts, a circuit may be traced, for'example, from the grid of tube H4 through lead 53 to the negative terminal of battery 'H4B, thence to the intermediate terminal of that "battery and through lead 52 to the cathode of tube H4. A similar circuit may be traced from the grid and cathode of tube H5 to the battery H5B through leads 6'! and and it will be noted that due to the position'of the copper inserts 29 and 30 the two tubes H4 and H5 will fire simultaneously. Thus there will be during the greater part of each revolution of the discs 1 MA and H'5B a negative bias onthe grids of tubes H4 and H5 in respect to their cathodes, preventing flowof current through said tubes.

At-the instant we are now considering, when brushes 29A and 29B and 30A and 30B make a simultaneous contact with their respective copper inserts 2-9 and 3|], a circuit may be traced, forexample, from the grid of tube H4 through leads-'53 and 66 to'the timer 62 where contact will be made between the leads 66 and 6|, provided button 65 is pushed down to make contact with leads '64, so'that the circuit may continue to be traced from lead 6| to brush 29A, insert 29, brush 29B, and lead 56 to the extreme positive terminal of battery H 4B, thence through the left portion of that battery and through lead 52 to the oathode oftube H4. The synchronous motor I8 and the'contact means 29 will be so adjusted that brushes 29A and 29B make contact with insert 29 at a desired predetermined moment, which according 'to selection may be set to occur prior to the peak positive voltage on the secondary of transformer 9|, or at its peak, or again at any time during the decline of said positive voltage. v

The above adjustment is one of several efiective means'for 'regulation'of energy used for welding,

It will be completed from the grid of tube H through loads 81 and E8 to the timer, where contact is made between leads 68 and 69, and through the brushes on disc 5A through lead 10, battery H53, and lead II to the cathode of tube I I5, to fire that tube simultaneously with the firing of tube I I4 and in.

the same manner.

Because the peripheral extension of the conductive inserts 29 and 30 are but a small fraction of the total periphery of discs I MA and I ISA, and because the brushes 29A and 29B and 30A and 30B are mounted in close proximity to each other, the span of time during which said brushes are simultaneously in contact with said inserts is rather small in comparison with the time re' quired for one complete revolution of the discs,

which, of course, constitutes the cycle of opera-- It is evident, therefore, that the positive-- voltage impulse produced by batteries H43 and- H513 on the grids of tubes H4 and H5 is of very small duration, said grids being maintained dur-- tion.

as in the case of tubes I I I and I I2. This happens when the voltage on the terminals of power condenser 2|, due to the increasing charge on its plates 20 and 22, balances the voltage of the secondary of the power supply transformer 9|. The current in the circuit through tubes H4, H5 and power condenser 2|, then ceases to flow, thus allowing the grids and the tubes H4 and H5 to regain their control.

The time required for the above charging of power condenser 2| depends upon the electrical parameters of the charging circuit, as has been explained before.

After a suitable period or pause, the duration of which may be selected as /120 of a second after tubes H4 and H5 cease firing in case the power transformer 9| is used, the tube ||6 Wi11 be fired. It will be noted that this tube normally has a negative bias on its grid from battery IIGB through leads l2 and I4, which may be traced similarly to tube H3. When the tube H6 is to be fired, the copper insert 32 will have arrived at a position where it is in contact with the brushes 32A and 32B, and will apply a positive potential to the grid of tube IIB from the left hand portion of battery IIBB through the leads- 2|,the current through the primary-winding I8,;

24 of the welding transformer will induce a cur-. rent in the secondary 45 thereof which will be applied by .the leads 46, 41 to the electrodes 48 and 49 and thence to the work 5|), 5|, giving a second welding current impulse.

, 'Ihe duration of the power condenser discharge However,

depends -:upon the electrical parameters of the discharge; circuit, as previously explained.

Shortly afterthe positivegrid voltage impulse initiating the'firing of the discharge tube is made,

-; the brushes 32A and 323 will cease making'the simultaneous contact with copper insert 32, and a negative bias" Will;- be restored to thegrid of tube IIG from the battery IIEB. However, said grid of tube IIB will regain its actual control and bar any further unwanted renewal of dis charge through tube l I6 only after the potential difference between theanode and cathode of said tube has sunk during the discharge of the power condenser 2| to less than the internal arc drop (which has a normal range of approximatelyb to 25-volts) of tube IIB, as in the case oftube" -The'discharge of the condenser 2|, of which plate ZU-is now positive, through the welding H6, is

transformer primary I8, 24-and tube exactly similar to the discharge of the condenser 2| when plate 22 is positive, through tube 3 and welding transformer primary I8, 24, except that the current is in the opposite ve'ctorial direction. Thus "the reverse charge built up in the condenser 2| in the-course of the collapse of the magnetic field in the welding transformer primary I8, 24, will now make plate 22 of condenser 2| positive. This charge is as much as 25 or more percentof the original condenser charge.

Such energy of inverse potential stored in con- I denser 2|, as explained in connection with the discharge through tube 3, remains trapped therein due to the valve action of tube I I6 which .bars any current surges of inverse direction from that it is not in firing condition at the proper' time to permit such surges to pass.

One full cycle of operation has now been de- "scribed, and such cycle may, of course, be repeated as often as desired.

In gener'al the currents and voltages in con- ,densefcharging circuits, aswell as in discharging circuits; have either aperiodic or oscillatory characters depending upon the relations between the electrical parameters of the respective circuits. Since the grids of the grid controlled gasfilled rectifier tubes which may be used in such circuits for unidirectional switching operations can regain their controls only at such times when there is no current flowing through such tubes, it

is obvious that the electrical parameters of the condenser charging or condenser discharging circuits should be so selected that the resulting charging or discharging currents, respectively, will have oscillatory characters only. 'This condition issatisfied by making the resistance of ,each of the charging and discharging circuits" respectively as low as possible in order to satisfy ductive to the capacitive parameters of said It will be noted that the successive surgesof welding current pass through-the primary, of the welding transformer in opposite vectorial dir.e c-; tions. This symmetryof successive surges produces-a flux density inthe welding transformer which is equal and opposite during successive welding current surges. This not only produces a welding current in the secondary of. the same "1 amplitude-and duration, but avoids misuse and;

- ficiency. prior. artstructures was thatthe welding results gardless of the pressure. over avery limited temperature range.

amass abuse'ofthe welding transformer. This permits the. employment of an efiicient, normally dimensioned closedcore weldingtransformer.

of the prior art, where all surges of current were in the same direction, the core of the transformer i would become highly magnetized and would be very inefiicient in operation, asit could operate only on the upper end of the magnetizing curve.

' This required the use ofover-sized iron cores, or

iron cores provided withair gaps, which resulted in a considerable decrease in transformer ef- An important disadvantage of such were inconsistent. That is, successive. welds on the same. work pieces from the same welding circuit through the same welding transformer,

which should have produced identical welding results, would. produce welds which in one case might be very satisfactory and the'next succeed- -ingweld might be totally unsatisfactory.

This disadvantage is. completely overcome by my apparatus in which the current through the welding -=transformer is alternately in opposite vectorial;

directions, as this permits reliably consistent results from each welding current impulse. The

.magnetization of the core in one direction by the discharge current from condenser 2i is overcome by the following surge of discharging current in the'opposite direction, just as occurs in any transformer in an alternating current line. My apparatus has an efficiency approximately 'double that of prior power condenser resistance welders. This results not only from the improved efficiency of the welding, transformer just discussed, but from other reasons, as well. I not only utilize the collapsing, field of the transformer 44 to continue supplying welding current to the work, but. also to store uppower in the inverse direction in the condenser 2 I, where that power jassists. the succeeding surge of charging. current instead of opposing it as in prior devices. Thus-I not only eliminate a residual charge which may be-a-s high as 25% or more, which needs to be overcome in prior devices, but utilize. this. in a beneficial way. I therefore require. only about ,half the current from the power mains for the sameamount ofwelding current supplied to the work. Furthermore, withrny invention I can do vseam welding and this is. an important use of my invention. Ithas not been-found possible. to do seam welding with prior powercondenser recal: properties of the work may therefore be altered so that they do not have the desiredqualities. Stainless steel and high carbon steel, for example, are very sensitive to overheating. Stainless steel may, in fact, be changed to nonstainless steel if overheated. Aluminum, aluminum alloys, copper and copper alloys will become brittleif overheated, and may burn without producing a real forged union at the spot re- Aluminum is plastic Where an attempt is. made to. weld aluminum over a period requiring longer or repeated application ,of heat, the tendency to produce a burning or overheating close to the electrodes is pronounced. In the case of welds requiring a number of welding current surges,v therefore, in my apparatus these disadvantages are overcome because each welding current surge is completed before the dirt or oxide films which may be present. excessive pressure is never necessary, which pressure might cause undesired bulging or indenheat or current can spread sufficiently to have theseundesired results.

With a power condenser welder the voltage applied to the-work may be as high as 100 volts and consequently sufficient' potential difference betweenthe electrode tips is available to overcome Thus tations.

I prefer to use a D. C. excitation for the synchronous motor 78 when a power transformer 9| is used, in order to assure synchronization of the discs IHA to I IGA with the power source, so thatI may effect-the charge and discharge of the condenser 21 always at exactly the same time with respect to the phase of current in the secondary ofthe power transformer.

Although electrical means may be employed to fire the switching tubes ill to H6, provided adequate electrical precautions are taken, I have found that it is highly desirable, if not essential, unless the electrical precautions are elaborate, thatmechanical control be used for most efiicient and consistent results. I accordingly employ the contact discs IHA to NBA run by the synchronous motor with'the copper inserts 2! to 32 and the brushes 21A to 323. This makes the timing of my apparatus much more certain, avoids electrical difficulties-in the welding due to disturbancesfrom the controlling circuit, and therefore assureselectrical symmetry in the welding circuit.

It also avoids disturbances from the welding circuit to the electrical controls, which disturbances might shift the time of firing or cut off the tubes to-such an extent as to cause this-firing or cut on to occur at the wrong time in the welding cycle, or to cause it to occur for too short, toolong, or uneven intervals dur- Well-as the welding transformer 44, by applying a step by step method of mathematical analysis,

the equivalent frequency of the charging and discharging surges being taken into account.

This equivalent frequency may range from -500 to 1500 cycles per second, or higher.

' It may be desirable in some circumstances to provide a time interval longer than /120 of a second between successive charging and discharging of the condenser '21. For example a machine of: very large kv.-a. rating might require iron cored transformers of such size that the charging surge and discharging surge would not be completed in a short enough time and might even partially overlap. Also different types of control tubes have different characteristics. In xenonfilled tubes, for example, de-ionization occurs very quickly so that the grid may regain control in a very shorttime. In mercury-filled tubes, however, tie-ionizationoccurs more slowly, depending upon the ambient temperature, so that if .mercury vapor tubes should be used a longer pause might be necessary. If for any reason such a longer pause is desired, this may be accomplished very simply by providing reduction gearing between the synchronous motor I8 and the discs IIIA to IIBA. For example, these discs might be rotated only once for each two or more cycles of current from the power mains. Let us assume, for example, that it is desired to rotate the discs only once for each five cycles. The reduction gearing would then be five to one. The tubes III and H2 would be fired and the condenser 2| charged during a portion of half of a cycle of the power supply. There would then be a pause for two and one-half cycles of the power supply, or for /24 of a second, before the firing of the tube H3. After another pause of /24 of a second the condenser 2| would again be charged through the tubes 4 and H5, and after another equal pause the tube II6 would be fired again to discharge the condenser 2|.

In the event I employ a rectifier 9 I, the timing of the charge and discharge of the condenser 2| and the duration of the welding current surges may likewise be adjusted as just described in connection with the use of a power transformer 9|. However, the use of power rectifier 9| permits some latitude of adjustments that is not present in the case of a power transformer since the intervals between the times of charge of condenser 2| are not dependent upon the frequency of the power source. Consequently with a power rectifier 9| I may space my surges of welding current closer together than with a power transformer 9|, depending upon the work to be done. I may also space the welding current surges at intervals which are not multiples of the frequency of the current from the power mains.

There is another important advantage in the use of a power rectifier, namely that it provides an equally distributed load on the power mains. It also provides a decreased impedance in the charging circuit because the rectifier may employ a six or twelve phase rectifier transformer with a corresponding number of rectifier tubes power supply, I may employ any type of constant speed motor to drive the discs I I IA to ISA instead of a synchronous motor with D. C. excitation, as illustrated in the drawing. Such a substituted constant speed motor might be a D. C.

shunt motor equipped with a governor control, and may of course have the motor speed ad- 'jus'table.

Although I have illustrated the welding electrodes 48 and 49 as rollers for seam welding, I may of course use fixed electrodes for spot welding.

The requirements as to the electrical parameters of the circuits shown will be understood from the following values given for a welder of kv.-a. rating with a circuit in accordance with the drawing.

Frequency of the A. C. power supply-60 cycles per second.

Rating of the power transformer 9I-5 kv.-a. with a 440 volt primary and a tapped secondary providing voltages from 100 volts in steps of 25 upwards to 500 volts. The secondary may be over-sized in order to cut down its resistance approximately 25%.

A which at any moment are acting partially in The primary of the welding'transformermay consist of two symmetrically located groups of coils. Each group may consist of four coils, adequately insulated from each other and from the core, of nine turns each of No. 6 gauge copper conductor. The secondary may consist oftwo single turn coils of laminated copper connected in parallel having a width each of 1.875 inches and a cross-sectional copper area of .6 square inch each. The core of the transformer should be laminated and closed and may be of a shell type, the central le having a cross-section of 1% x 3 inches, or 5% square inches.

The condenser 2| may consist of several units having a total capacity ofv 112.5 microfarads, with taps for each 12.5 microfarads, thus providing means for varying the capacity by using more or less of these units.

Thetubes III, H2, H4 and IISmaybekryptonfilled grid controlled tubes of Electrons, Inc., No. 06C. The rectifiers H3 and H6 may be the same with the grids tied through 20,000 ohm resistors to the respective cathodes.

The rectifier 9| may be of any suitable type but preferably comprises a 6 phase transformer equipped with 6 rectifying tubes, and in case of 30 kv.-a. may consist of C6D type krypton-filled rid controlled tubes manufactured by Electrons, Inc.

The voltage of the right hand portion of batteries IIIB to IIBB may be between 25 to 35 volts, and in the left hand portion may be between 10 and 25 volts.

In practice all of the battery voltages would normally be obtained by the use of rectifiers and potentiometers, the batteries being shown to simplify the diagram.

In the case of a 15 kv.-a. welding machine, the weldin transformer primary may consist of 160 turns total, wound in two coils of turns each. Each coil may consist of four sections of 20 turns each. When all sections are connected in parallel, the active primary turns will be 20. The secondary may consist of two coils of one turn each connected in parallel. Each primary conductor may be .162 x .325 inch of bare copper. The cross-section of each of the laminated secondaries may be 1.98 square inches. The core may be of a laminated shell type and the net cross-section of the center leg of said core may be 21.9 square inches with a total weight of the core of about 230 pounds. The condenser 2| may consist of a bank of condensers connected in parallel, having a total capacity of 150 microfarads arranged with taps to permit use of less than the total capacity when the machine is used at less power, or to regulate the performance for the particular job being done and the values of other electrical parameters. C60 tubes have been found satisfactory for 15 kv.-a., although a larger type C6D may be used to advantage.

The secondary voltage of the power transformer 9| may be about 1000 volts R. M. S.,'the secondary being provided with taps of volts each and the secondary conductor being about 25% over-sized to cut down the resistance and thus reduce the secondary impedance.

From the above description it will be apparent that this invention resides in certain principles of construction and operation as illustrated in the drawing. It is recognized that those skilled in the art may readily vary the application of these principles and the structure by which they are applied without departure from the scope of this invention. I do not, therefore, desire to be 13 strictly limited to the description as given for purposes of illustration, but rather to the scope of the appended claims.

What is claimed:

1. A resistance welder comprising a circuit including a welding transformer, an energy storing device, a power transformer, means for successively charging said device alternately to opposite polarity from said power transformer, means for discharging said device by surges of current alternately in opposite vectorial directions through the primary of said welding transformer in timed relation with phase of voltage in said power transformer, and unidirectional means effecting inverse charging of said device during the collapse of the magnetic field in said welding transformer.

2. A resistance welder comprising a circuit including a welding transformer, an energy storing device, a source of direct current, a plurality of gas-filled controlled rectifier type tubes arranged in a bridge connection, means for alternately firing pairs of said tubes simultaneously to charge said device alternately to opposite polarity from said current source, a pair of additional gas-filled controlled rectifier type tubes, means for alternately firing said additional tubes to discharge said device by surges of current alternately in opposite vectorial directions through the primary of said welding transformer and to charge said device inversely during the collapse of the magnetic field in said welding transformer.

3. A resistance welder comprising a circuit including a welding transformer, an energy storing device, a source of current, means for charging said device alternately to opposite polarity from said current source, means for releasing surges of energy from said device alternately in opposite vectorial directions through the primary of said welding transformer, and uni-directional means effecting inverse charging of said device during the collapse of the magnetic field in said welding transformer.

4. A resistance welder comprising a circuit including a welding transformer, an energy storing device connected effectively to the primary of said transformer, a source of current, means for successively charging said device to opposite polarity from said current source, means for successively discharging said device in opposite vectorial directions through the primary of said welding transformer, and means effecting a surge of useful energy into said device during the collapse of the magnetic field in said welding transformer following each discharge of said device therethrough.

5. A resistance welder comprising a circuit including a welding transformer, an energy storing device, a source of current, means for successively charging said device from said current source, means for successively discharging said device alternately in opposite vectorial directions through the primary of said welding transformer, and means effecting inverse charging of said device during the collapse of the magnetic field in said welding transformer following each discharge of said device therethrough.

6. A resistance welder comprising a circuit including a welding transformer, an energy storing device, a source of current, means for successively charging said device from said current source, and switching means in series with said welding transformer primary during the discharge of said device, operating in timed relation with maximum voltage on said device, to effect successive discharges of said device alternately in opposite vectorial directions through said welding transformer primary.

'7. A resistance welder comprising a circuit including a welding transformer, a power condenser, a source of direct current, means for charging said power condenser from said source, means for discharging said power condenser through the primary winding of said welding transformer in alternately opposite vectorial directions to effect complete demagnetization of the core of said welding transformer for the purpose of obtaining maximum efficiency of said transformer, and means for effecting a vectorially reversed storing of energy in said power condenser released by the collapse of the magnetic field in said welding transformer following each discharge of said power condenser therethrough for the purpose of retrieving said energy during successive charging of said condenser.

ALEXANDER RAVA.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS 

